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Profile-based design is widely used because of its flexibility. A good possibility to increase the lightweight aspect can be the use of fiber reinforced profiles. These can be produced in a series suitable process - pultrusion. In this paper, the integration of functions in pultrusion profiles is focused. In one project, potential sensor concepts for robust condition monitoring of fiber reinforced plastic (FRP) profiles were developed to expand the range of applications significantly. One application could be the substitution of complex aluminum profiles by fiber reinforced profiles with the advantage like high lightweight potential and low thermal expansion. Another objective was the integration of sensors and light-emitting diodes (LED) directly into the pultrusion profile. The objective of a second research project was the integration, wiring and test of sensors into a curved roller ski profile to detect loads during training. Several types of sensors were investigated to evaluate the parameters accuracy, positioning, and wiring at the best economic efficiency. The focus of the research and development of both projects was the integration of functions into pultruded profiles made of FRP. Successfully integrated functionalizing elements include sensors for strain, lighting elements, and touch sensors as well as temperature and humidity modules. The objective of the research project “SmartSensSki” was the integration, wiring and test of sensors into a curved roller ski profile to detect loads during training. Several types of sensors were investigated to evaluate the parameters accuracy, positioning, and wiring at the best economic efficiency. The focus of the research and development of both projects was the integration of functions into pultruded profiles made of FRP. Successfully integrated functionalizing elements include sensors for strain, lighting elements, and touch sensors as well as temperature and humidity modules.

Composites made of carbon-fiber-reinforced carbon (C/C or CFC) are high-performance materials with a wide range of properties, making them especially suitable for the design of thermally and mechanically highly stressed components. As the production process of these high-performance materials is currently still very expensive, new concepts for an economical manufacturing process are required. This paper focusses on an innovative approach that uses the polymer-based pultrusion process for shaping with a subsequent carbonization step to C/C. In this process, carbon fibers (CF) and a phenolic resin were used to manufacture a semi-finished product made of unidirectional (UD) carbon-fiber-reinforced plastic (CFRP) with a fiber volume content of 66%. The C/C composite shows dimensional stability and has a flexural strength of approx. 240 MPa and a flexural modulus of approx. of 135 GPa with an elongation of 1.8%.

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The development of multi-material hybrids by injection molding has been studied very intensively at the IPF in the past. For that, a material bonding between the different substrates was achieved by using a newly developed two-step curing powder coating material as latent reactive adhesive. The aim of the project “Hybrid Pultrusion” was to perform a novel approach for the fabrication of material bonded metal-plastic joints (profiles) in a modified pultrusion process. Therefore, powder pre-coated steel coil is combined with a glass-fiber reinforced epoxy resin matrix. For initial basic studies, the impregnated fiber material has been applied on the pre-coated steel sheets using the Resin Transfer Molding process (RTM-process). It was proved via lap shear tests, that this procedure resulted in very high adhesive strengths up to 35 MPa resulting from the formation of a covalent matrix-steel bonding as well. In addition, the failure mechanism was subsequently studied. Furthermore, by adapting the successful material combination to the pultrusion process it was demonstrated that material bonded hybrids can be achieved even under these continuous processing conditions.